Fluid filters and methods of use

ABSTRACT

Multiple staged filters are provided herein. A filter may include a plurality of panels that each include a filtering front surface and a flat back surface, the filtering front surface having a first row of vertically extending protrusions spaced apart from one another to form vertical channels, a second row of vertically extending protrusions spaced apart from one another to form vertical channels, and one or more rows of filtering protrusions, where the one or more rows are vertically spaced apart from one another and extending between the first and second rows of vertically extending protrusions. Further, each row of filtering protrusions may include filtering protrusions that are spaced from one another to form filter channels having a size that is configured to receive and retain objects of a given size.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional U.S. patent application claims the priority benefitof U.S. Provisional Application Ser. No. 61/848,671, filed on Jan. 9,2013, titled “FILTER WITH MULTIPLE STAGES TRANSVERSELY ORIENTED”, whichis hereby incorporated by reference herein in its entirety including allreferences cited therein. This application is also related to U.S.Provisional Application Ser. No. 61/849,098, filed on Jan. 17, 2013,titled “FILTER WITH MULTIPLE STAGES TRANSVERSELY ORIENTED IMPROVED” andU.S. Provisional Application Ser. No. 61/851,987, filed on Mar. 14,2013, titled “FILTER WITH LAYERED CONSTRUCTION” all of which are herebyincorporated by reference herein in their entireties including allreferences cited therein.

FIELD OF THE INVENTION

The present technology is directed to filters, and more specifically,but not by way of limitation, to filters that comprise multiple stagedlayers which are alternatingly and transversely oriented to one another.These filters advantageously are configured to filter a particulatebearing fluid to remove particles of various sizes.

BACKGROUND

Fluid filters are utilized to separate particulate matter that isdispersed in a fluid. For example, fluid filters are used to desalinatewater, purify lubrication fluids in mechanical devices, and removeparticular matter from air or other gaseous fluids. Examples of filtersinclude U.S. Pat. No. 6,524,488, which describes a filtration mediaformed from at least one structured polymeric layer, wherein astructured surface is defined within the layer. Layers may be configuredas a stack that has the structured surfaces defining a plurality ofordered inlets open through a face of the stack and correspondingordered fluid pathways, thereby forming an ordered, porous volume. Theordered fluid pathways may be defined by a plurality of flow channelsformed within the structured surfaces of the structured layers, or maybe defined by a plurality of protuberances formed in an ordered patternwithin the structured surfaces of the structured layers. Also, U.S. Pat.No. 7,282,148 describes an asymmetric filter membrane, and process formaking the same. The membrane structure is physically robust andsuitable for use in a wide variety of applications. The support membraneis may be comprised of material such as a porous silicon or a siliconoxide, and the separation membrane may be comprised of material such asa polymer, zeolite film, or silicon oxide. The process relies on stepsadapted from the microelectronics industry.

Further, US 2012/0267249 describes a filter that includes a membranehaving a plurality of nanochannels formed therein. A first surfacecharge material is deposited on an end portion of the nanochannels. Thefirst surface charge material includes a surface charge toelectrostatically influence ions in an electrolytic solution such thatthe nanochannels reflect ions back into the electrolytic solution whilepassing a fluid of the electrolytic solution. Methods for making andusing the filter are also provided.

SUMMARY OF THE PRESENT TECHNOLOGY

According to some embodiments, the present technology may be directed toa filter device, comprising a plurality of panels, each of the pluralityof panels comprising a filtering front surface and a flat back surface,the filtering front surface comprising: a first row of verticallyextending protrusions spaced apart from one another to form verticalchannels, the first row proximate an inlet of the filter device; asecond row of vertically extending protrusions spaced apart from oneanother to form vertical channels, the second row proximate an exit ofthe filter device; one or more rows of filtering protrusions, the one ormore rows being vertically spaced apart from one another and extendingbetween the first and second rows of vertically extending protrusions,each row of filtering protrusions comprising filtering protrusions thatare spaced from one another to form filter channels having a size thatis configured to receive and retain objects of a given size; and whereinthe plurality of panels are stacked in a mating configuration such thatthe filtering front surface of one panel is in mating contact with theflat back surface of an adjacent panel.

According to some embodiments, the present technology may be directed toa substrate panel for filtering a fluid, the substrate panel, comprisinga filtering front surface and a flat back surface, the filtering frontsurface comprising a first row of vertically extending protrusionsspaced apart from one another to form vertical channels, the first rowproximate an inlet of the filter device; a second row of verticallyextending protrusions spaced apart from one another to form verticalchannels, the second row proximate an exit of the filter device; and oneor more rows of filtering protrusions, the one or more rows beingvertically spaced apart from one another and extending between the firstand second rows of vertically extending protrusions, each row offiltering protrusions comprising filtering protrusions that are spacedfrom one another to form filter channels having a size that isconfigured to receive and retain objects of a given size.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the present technology are illustrated by theaccompanying figures. It will be understood that the figures are notnecessarily to scale and that details not necessary for an understandingof the technology or that render other details difficult to perceive maybe omitted. It will be understood that the technology is not necessarilylimited to the particular embodiments illustrated herein.

FIG. 1 is an isometric view of a section of a filter.

FIG. 2 is an isometric view of one panel of the filter.

FIG. 3 is a front view of one panel of the filter shown in FIG. 2.

FIG. 4 is an isometric view of an alternate filter panel.

FIG. 5 is an isometric view of another alternate filter panel.

FIG. 6 is a close-up view of FIG. 5.

FIG. 7 is a close-up view of another alternate filter panel.

FIG. 8 is an isometric view of a spiral configuration of the filter.

FIG. 9 is an isometric view of a circular configuration of the filter.

FIG. 10 is an isometric view of a conical configuration of the filter.

FIG. 11 is a front view of an alternate bypass filter panel.

FIG. 12 is an isometric view of an alternate filter panel.

FIG. 13 is an isometric view of an alternate filter panel.

FIG. 14 is an isometric view of an alternate filter panel.

FIG. 15 is a front view of an alternate filter panel.

FIG. 16 is a front view of an alternate filter panel.

FIG. 17 is a front view of an alternate filter panel.

FIG. 18 is an isometric rear view of an alternate filter panel.

FIG. 19 is an isometric view of an alternate filter panel.

FIG. 20 is an isometric view of an alternate filter panel.

FIG. 21 is an isometric view of an alternate filter panel.

FIG. 22 is a close-up view of FIG. 21.

FIG. 23 is a close-up view of FIG. 22.

FIG. 24 is a back side cut away view of an alternate filter.

FIG. 25 is an isometric view of a section of the filter.

FIG. 26 is a front view of one panel of the filter.

FIG. 27 is a back view of one panel of the filter shown in FIG. 26.

FIG. 28 is top section view of the filter.

FIG. 29 is an isometric view of the filter.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

In the following description, for purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of the disclosure. It will be apparent, however, to oneskilled in the art, that the disclosure may be practiced without thesespecific details. In other instances, structures and devices are shownat block diagram form only in order to avoid obscuring the disclosure.

Reference throughout this specification to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is includedin at least one embodiment of the present invention. Thus, theappearances of the phrases “in one embodiment” or “in an embodiment” or“according to one embodiment” (or other phrases having similar import)at various places throughout this specification are not necessarily allreferring to the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more embodiments. Furthermore, depending on the context ofdiscussion herein, a singular term may include its plural forms and aplural term may include its singular form. Similarly, a hyphenated term(e.g., “on-demand”) may be occasionally interchangeably used with itsnon-hyphenated version (e.g., “on demand”), a capitalized entry (e.g.,“Software”) may be interchangeably used with its non-capitalized version(e.g., “software”), a plural term may be indicated with or without anapostrophe (e.g., PE's or PEs), and an italicized term (e.g., “N+1”) maybe interchangeably used with its non-italicized version (e.g., “N+1”).Such occasional interchangeable uses shall not be consideredinconsistent with each other.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presenceof stated features, integers, steps, operations, elements, and/orcomponents, but do not preclude the presence or addition of one or moreother features, integers, steps, operations, elements, components,and/or groups thereof.

It is noted at the outset that the terms “coupled,” “connected”,“connecting,” “electrically connected,” etc., are used interchangeablyherein to generally refer to the condition of beingelectrically/electronically connected. Similarly, a first entity isconsidered to be in “communication” with a second entity (or entities)when the first entity electrically sends and/or receives (whetherthrough wireline or wireless means) information signals (whethercontaining data information or non-data/control information) to thesecond entity regardless of the type (analog or digital) of thosesignals. It is further noted that various figures (including componentdiagrams) shown and discussed herein are for illustrative purpose only,and are not drawn to scale.

The present invention relates to filters for the filtering of orseparation of different sized particles. A common use of a filter is inautomobiles and trucks. Filters are used to remove solid particles fromthe air used by internal combustion engines. Filters are also used toremove particles from the oil used in both engines and transmissions.

Typically filters used in these applications use a membrane with smallapertures to remove particles from the air or oil. The material is oftenfolded many times to create as much surface area of filter material in asmall overall area.

Smaller sized apertures in the membrane capture smaller sized particles.These smaller apertures also create more restriction in the flow ofeither a fluid or gas that is being filtered therethrough. In the caseof an air filter for internal combustion engines, smaller apertures mayresult in reduced performance and reduced fuel economy. If the aperturesare made larger, performance increases but engine life is reduced.

Filter type structures can also be used to separate different sizedparticles from a fluid. Separation of particles can be used to separatebiological materials or different sized molecules from a fluid.

The desalination of water is one area where filter material is used toseparate different sized molecules. This task requires the removal ofsodium chloride molecules from smaller water molecules. For thedesalination of salt water the relative amount of sodium chloride inrelationship to the water molecules is high. Because of this high ratio,a significant amount of sodium chloride is collected in the filter whenprocessing modest amounts of water.

According to some embodiments, the present technology is directed to afilter with a number of layers of panels or films in combination withstructured elements that are laminated together to form a series ofchannels which filter or trap specific sizes of particles or molecules.The panels have an entrance region formed of relatively wide channelswhere only large particles are restricted. These entrance regions alsofacilitate the slitting of the panel during manufacturing. Following theentrance region are a series of progressively narrower channels thatrestrict the passage of particles. A transverse channel between thefilter channels allows for a cross matrix of flow from adjacent channelsof differing width.

As background, typically an entire row of structures would comprise onlyone width of channels. For a bypass type filter typically used in oilfiltration, a row may have different width channels. For instances wherea significant percentage of one specific sized particle or molecule isto be filtered there would be a series of bypass rows to collect therelative large quantity of the specific sized particles or molecules.

Further rectangular cross sectioned filter channels allow for moreefficient collection of generally round type particles or molecules. Toreduce restriction of flow, radii may be added to the leading andtrailing edges of the channels.

Referring first to FIG. 1, which illustrates an example of a filter 1that is constructed in accordance with the present technology. Fluid orgas flows into the filter 1 from the top surface 2 or “inlet” of thefilter 1. The filter panels 3 are layered together where the top edges 4of the filter panels 3 forms the top surface 2 of the filter 1. Thenumber of filter panels 3 layered together will vary according to designrequirements as would be appreciated by one of ordinary skill in theart. In some embodiments, the number of filter panels 3 may be in thehundreds or thousands. The width of the filter panels 3 may also varyaccording to design requirements or specifications, including, but notlimited to, the application for the filter (e.g., desalinization versuscabin air filtering in a vehicle).

Each panel 3 comprises a filtering front surface 1A and a flat backsurface 1B (see FIG. 18). The panel 3 also includes a pair of flanges 1Cand 1D which are disposed along the outside edges of the panel 3. Theseflanges serve to provide structural support to the panel 3.Additionally, when panels are stacked, the panels will mate together atleast at their flanges.

An exemplary filter (substrate) panel 3 includes a first row ofvertically extending protrusions 4A that are disposed near the topsurface 2 of the panel 3, as well as a second row of verticallyextending protrusions 4B disposed near a bottom surface of the panel 3.The vertically extending protrusions the first row are preferably spacedapart from one another to form vertical channels 5A. Likewise, thevertically extending protrusions the second row are preferably spacedapart from one another to form vertical channels 5B.

It will be understood that a vertically extending protrusion mayinclude, for example, a rectangular dentil or block shaped object thatextends normally from the surface of the panel 3. These protrusions mayhave a consistent shape and size relative to one another, or may beirregular in both shape (e.g., square, triangular, rectangular) and size(e.g., height, width, length).

The vertical channels 5A and 5B in the filter panel 3 are arrangedvertically along the horizontal length of the top edge 4 of the filterpanel 3. The number of vertical channels 5A and 5B may vary inaccordance with design specifications. In some embodiments, the panel 3may comprise hundreds or thousands of the vertical channels 5A and 5B.In some embodiments all of the channels of the filter 1 would bearranged together or configured to create a consistent pattern,producing a filter 1 of having a consistent cross-sectional area.Although, for different applications of the filter, different patternsof filter panels may be layered together in varying or irregularpatterns.

In some embodiments, the filter panel 3 comprises one or more rows offiltering protrusions 5C. For example, the panel of FIG. 1 includes sixrows of filtering protrusions. Additional details regarding verticallyextending protrusions and rows of filtering protrusions are described ingreater detail relative to FIG. 2.

Referring to FIG. 2, only one filter panel 3 is shown. The verticalchannels 5A and 5B are generally equally spaced and the same sizerelative to one another. The width of each of the upper verticalchannels 5A is ideally larger than most of the particles dispersedthrough the fluid. For example, the vertical channels 5A might be 200microns in width and 200 microns in depth. The horizontal spacing of thevertical channels 5A in the filter panel 3 might be 300 microns, whereasthe entire thickness of the filter panel 3 might be 300 microns.

It will be understood that the closer the thickness is to the depth ofthe channels the greater the overall density of the filter 1. Forexample, the height of the vertical channels 5A might be 500 microns.This relative large dimension allows for variations in the manufacturingprocess of the filter panel 3. For greater ease of manufacturing thevertical channels 5 might be taller than 500 microns. In otherembodiments the vertical channels 5 may have a height that is shorterthan 500 microns if a more compact filter is desired.

The vertical channels 5A terminate in the first cross channel 6. Thefirst cross channel 6 extends, in one embodiment, from the left side ofthe vertical channels 5A to the far right side of the vertical channels5A. The height of the first cross channel 6 might be 200 microns andwould preferably be the same depth as the vertical channels 5A.

Referring to FIG. 3, where the filter panel 3 is shown in a front viewwith arrows depicting fluid flow. The flow exits the vertical channels5A and flows into the first cross channel 6.

The fluid then encounters the first of a plurality of rows of filteringprotrusions. By example, a first row of filtering protrusions 7A mayinclude filtering protrusions that are spaced from one another to formfilter channels 7B. Each of the filter channels 7B are sized to receiveand retain objects of a given size, such as particles dispersed in thefluid that flows through the panel 3.

The panel 3 includes six rows of filter protrusions that form filterchannels. The filter channels for a given row are substantially the samesize. Additionally, the filter channel size is reduced in relation tothe position of the row. For example, the width of the filter channelsof the row closest to the vertical channels 5A are larger than the widthof the filter channels of the row closest to the vertical channels 5Bthat are proximate the exit of the filter panel 3. The widths of filterchannels of rows therebetween become successively smaller.

Thus, the panel 3 is “multi-staged” because it includes more than onerow of filtering protrusions that are arranged so as to captureparticles dispersed in a fluid in such a way that larger particles aretrapped in upper rows of the filtering protrusions and progressivelysmaller particles are trapped in other, lower rows of filteringprotrusions that form filtering channels.

It should be noted that the limiting factor for the particle size to betrapped in the filters described herein may be either the width or thedepth of the filter channels. In some cases it may be preferable tocontrol the size of the particle trapped via depth due to the ability todeposit very thin layers of materials. For example, the practical sizelimit for protrusions created by lithography is approximately 14nanometers. Deposition allows a user to control channel depth to roughlythe size of an atom, or approximately 1 nanometer.

The fluid or gas can flow into a filter channel 7C directly under thevertical channel 5A or it can flow to the neighboring filter channel 7D.In fact the fluid may flow to any of the row of first filter channels tothe left or the right. In some embodiments, the width of each of the rowof first filter channels is narrower than the width of the verticalchannels 5A.

In one embodiment, the first row of filter channels might be 130 micronswide, 70 microns narrower than the vertical channels 5A. The horizontalspacing may also be narrower, from 300 microns of the vertical channels5 to 200 microns. The first row of filter channels may not allowparticles in the fluid or gas to pass through if they were greater thanthe 130 micron width.

It should be noted that the depth of the first row of filter channelshave a similar width as the other channels, for example, 200 microns. Soan asymmetric particle having a minor width of less than 130 micronscould pass through the first row of filter channels even though someportion of the particle is wider than 130 microns.

In some embodiments, the first row of filter channels 7B is much shorterthan the vertical channels 5A. The first row of filter channels 7Bterminates at the second cross channel 9. The second cross channel 9 issimilar to the first cross channel 6 except it might be shorter inheight, 180 microns for example. The second cross channel 9 extends, atminimum, from the left vertical channels 5A to the far right verticalchannels 5A.

The fluid or gas can flow from the second cross channel 9 to the secondrow of filter channels 10 directly under the first row of filterchannels 7B. Again, the second row of filter channels 10 is formed by asecond row of filter protrusions 10A that are spaced apart from oneanother. As mentioned above, the width of the second row of filterchannels 10 may be smaller than the width of the first row of filterchannels 7B.

A particle 11 is shown as lodged in a filter channel of the second row,between two adjacent filter protrusions of the second row. The depth ofthe particle 11 effects whether an adjacent filter channel is entirelyor partially blocked. Regardless, the particle 11 at least partiallyblocks a neighboring filter channel in this example. The second crosschannel 9 allows the blocked flow to flow to other filter channels inthe second row.

Again, additional rows of filter protrusions and filter channels arerepeated with smaller and small feature sizes to create a multi-stagedfilter with accurate control of particle collection and retention. Insome instances, adjacent rows of filter protrusions may be offset fromone another. For example, the first row of filter protrusions 7A may beoffset from the second row of filter protrusions 10.

The filter panels 3 would typically be made by molding the features intoa plastic film. The tool used to mold the channels would be a negativeto that of the filter panels 3. The features in the tool could bemachined in the tool with precision machining processes, etched, or thefeatures could be made with semiconductor manufacturing type processes.One knowledgeable in the art of fabrication tools with micro or nanosized features could devise the best method to fabricate a tool for aspecific filter design. It should be noted that the accuracy ofsemiconductor type manufacturing processes can be extremely high. Thisresults in extremely accurate widths of the fluid channels in the panels3 of the filter 1, allowing for accurate and exact filtering ofparticles. This is especially important when the filter is used toseparate different sized particles.

As mentioned above, after the last row of filter protrusions there arethe exit vertical channels 5B, which are configured to direct thefiltered fluid out from the filter 1.

Referring to FIG. 4, a filter panel 43 of a single stage filter isshown. The single stage filter would be used to separate a specificparticle of greater than one size. The filter panel 43 includes an inlet43, vertically extending protrusions 45, and a row of filteringprotrusions 46 that form filtering channels. FIG. 5 illustrates anexemplary filter panel 53 in the form of a bypass type filter. The panel53 includes vertically extending protrusions 55, a cross channel 56, anda plurality of rows of filtering protrusions 57 that form filteringchannels. FIG. 6 is a close-up of the bypass area in FIG. 5. This typeof filter would be used with a fluid that is circulated many timesthrough the filter such as an oil filter for an internal combustionengine.

Two different width filter channels are located along one row. Some ofthe fluid flows through the narrow channels 20, also referred to as a“filter groove”. The narrow channels filter out tiny particles and arealso restrictive to the flow. Most of the fluid flows through the lessrestrictive wide channels 21 (e.g., filter channels). When it is notessential that extremely small particles be filtered out on the firstpass through the filter panel 3 and if the restriction of the filter isa concern, this type of filter may be utilized. In every pass of fluidthrough the filter panel 3 an increasing number of the small particlesare removed from the fluid.

Referring to FIG. 7, another alternate bypass type filter design isshown. Two rows of filter channels have both narrow 20 and wide width 21filter channels. This type of filter may be used to remove a largequantity of a specific sized molecule such as sodium chloride molecules.With the desalinization of salt water the concentration of saltmolecules is high. Thus, by incorporating multiple rows of bypass filterchannels a greater quantity of sodium chloride molecules can be removedby the filter before the fluid channels are all blocked. Withdesalinization it is desired that virtually all the salt be removed fromthe water. The last row of filter channels would be all be narrower thanthe sodium chloride molecules. It should be noted that the quantity ofbypass rows and the width, depth and length of the filter channels willvary according to design requirements and application specifications.

Referring to FIG. 8, an alternate configuration of the layers of thefilter panel 3 is disclosed. By rolling one filter panel 83 in a spiralmanner a round filter 83 can be created. The filter 83 may bemanufactured in a roll-to-roll manufacturing process.

Referring to FIG. 9, an enclosed spiral filter 91 as shown in FIG. 8 isshown. The filter 1 is encased in a square frame 51 and the center holein the spiral filter 50 is filled with a center plug 52. This type offilter assembly might be used for filtering air used by an internalcombustion engine.

Referring to FIG. 10, an alternate arrangement of the filter 91 is shownconfigured in a cylindrical manner. This type of arrangement isapplicable to internal combustion engine oil filters.

Referring to FIG. 11, another arrangement of the filter panel 1100 isshown. The separation wall 60 allows for channels to flow into multiplerows of equally sized (or differently sized) filter channels. This typeof arrangement would also be useful for the separation of a largeconcentration of one particle size, such as with desalinization. Again,salt water is an example of a fluid with a high concentration of onesized particle.

Referring to FIG. 12, the filter panel 1200 is shown with the depth ofthe filter channels equal to the width of the filter channels creatingsquare filter channels 70. This geometry would filter particles where atleast two orthogonal dimensions of the particles are greater than thewidth, and depth of the filter channel.

Referring to FIG. 13, the filter panel 3 features are shown to havedraft or tapering. The pane 1300 comprises vertically extendingprotrusions 1305, an inlet 1310, and a first cross channel 1315, as wellas rows of filtering protrusions. Draft or draft angle is the amount oftaper put in the mold to facilitate the removal of the molded or castparts. Draft is often used in the molding process. The taper created bythe draft reduces the force required to extract the filter layer fromthe molding tool. The draft at the channels does not affect the functionof the filtering. So having larger rather than smaller draft would mostlikely be utilized. Draft of the filter channel walls does effect thefiltering. Specifically, it would allow a slightly wider range ofparticles to pass through a filter channel.

Referring to FIG. 14, radii 81 and fillets 80 are shown on thevertically extending protrusions and the filter protrusions of a panel1400. These radii or fillets can be incorporated to improve themanufacturability of either the filter layer or the tool to manufacturethe filter layer.

Referring to FIG. 15, the filter protrusions 90A are shown with angledtapered walls such that the filter channels 90B widen as the fluid flowsthrough the filter channel of a panel 1500. The addition of this taperallows capture of particles that are less likely to be trapped in thechannel. The particles would only be trapped at the inlet portion 90 ofthe filter channel and not the wider outlet portion 91. This type ofchannel might be deployed when it is desirable to recover the filteredparticles after the fluid is filtered. This would be useful whenseparating a specific sized cell or particle to later be used in anotherprocess.

Referring to FIG. 16, the filter panel 1600 is shown with two separationwalls 60 next to one another. The filter 1600 also includes featuresfound in the panel of FIG. 1 such as an inlet 4, vertical protrusions5A, and so forth. FIG. 16 further shows separation walls 60 disposedbetween rows of filtering protrusions 60A and 60B. The number ofseparation walls in the vertical direction, such as separation wall 60C,could also be numerous. Having a relatively large number of verticallystacked separation walls 60 would allow the filter to collect a largenumber of a specific sized particle. It should be noted that for smallparticles, the center-to-center spacing of the separation walls 60 maybe from only one to 100 microns. With a spacing of ten microns 100separation walls 60 could fit in a one millimeter high area.

Referring to FIG. 17, the filter panel 1700 is shown with a section 1705coated with a thin layer of a different material than the base material.This thin layer may be absorbent, leading to the separation of thesample components. These interactions are physical in nature, such ashydrophobic (dispersive), dipole-dipole and ionic, and are most often acombination thereof. It should be noted that more than one differenttype of material could be coated along the filter path. The differentareas might have different sized filter channels.

Referring to FIG. 18, the filter 1800 is shown with electrically chargedsurfaces. For example, the back surface 1B of each panel may be charged.Further, the charge alternates with each panel such that positivecharged panels are alternated with negatively charged panels. Thesecharges can be used to attract particles to the walls of the filterchannels. The charge could be imbedded in the filter material if thematerial was a polymer. A layer of conductive material could be added tothe surface of the filter panel with the conductive material charged byan external voltage source.

Referring to FIG. 19, some of the filter channels are shown to beshallower than other channels, while in FIG. 20 the filter is shown witha light source 2010 directed at the filter normal to the plane formed bythe flow. Again, the filters 1900 and 200 also may each include featuresfound in the panel of FIG. 1 such as an inlet 4, vertical protrusions5A, and so forth. A photo detector 2005 is positioned on the oppositeside of the filter. The light source and photo detector may be of oneparticular spectrum and may be UV, visible, IR or other wavelengths ofthe electromagnetic spectrum. This source/detector pair can be used todetect the presence of material and more important specific types ofmaterial at specific locations in the filter.

Referring to FIG. 21 and the close-up FIGS. 22 and 23, a preferreddesign of an air filter is shown. Referring to FIG. 23, the verticalchannels 5 (formed by spaced apart vertically extending protrusions)feeds the angled channels 110. In some embodiments, the angled channels110 extend downwards from the vertical channels 5 at approximately 30degrees from vertical. The angled channels 110 feed the micro filterchannels 111. Hundreds of the micro filter channels 111 are arrangedalong each of the angled channels 110. The fluid flows from the verticalchannels 5 to the angled channels 110 and is filtered by the microfilter channels 111. The fluid exits the micro filter channels 111 tothe angled exhaust channels 112. The angled exhaust channels 112 aredisposed generally parallel with the angled filter channels 110. Thefluid then flows from the angled exhaust filter channels 112 to the exitvertical channels 13.

Referring to FIG. 24, the back side of the filter 2400 can be seen withsome layer cut away. The layers between the filter panels are coatedwith an adhesive to ensure there are no gaps between the filter panels.This adhesive may be used with any of the configurations of filters orfilter panels. A solvent or heat and pressure may also be used to ensurethere are no gaps between the filter panels.

Referring first to FIG. 25, the filter 2500 is shown. Fluid or gas flowsinto the filter 1 from the top surface 2 of the filter 2500. The filterpanels 3 are layered together where the top edge 4 of the filter panels3 forms the top surface 2 of the filter 2500. The number of filterpanels 3 layered together would be much greater than what is shown. Thenumber of filter panels 3 may be in the hundreds or thousands. The widthof the filter panels 3 would also typically be much greater than what isshown.

The vertical channels 5 in the filter panel 3 are arranged verticallyalong the horizontal length of the top edge 4 of the filter panel 3. Thenumber of vertical channels 5 would generally be much greater than whatis shown in the FIG. 25. In some embodiments there would be hundreds orthousands of the vertical channels 5. Typically all of the filter 2500would be of the same pattern. Although, for different applications ofthe filter 2500, filter panels 3 having different patterns of rows offiltering protrusions may be layered together. For example, the panelsof FIGS. 2, 6, 7, and 11-17 may be used in various combinations,although any panel configuration and combination illustrated in thecollective drawings can also be utilized in accordance with the presenttechnology.

Referring to FIG. 26, only one filter panel 3 is shown. The verticalchannels 5 are generally equally spaced and the same size. The width ofthe vertical channels 5 would be larger than most of the particles beingfiltered. The vertical channels 5 might be one micron in width and 0.6micron in depth. The horizontal spacing of the vertical channels 5 inthe filter panel 3 might be ten microns. The entire thickness of thefilter panel 3 might be one micron. It will be understood that thecloser the thickness is to the depth of the channels the greater theoverall density of the filter.

The height of the vertical channels 5 might be three microns. Thisrelative large dimension allows for variations in the manufacturingprocess of the filter panel 3. For greater ease of manufacturing theymight be taller. They may also be shorter if a more compact filter isdesired.

The vertical channels 5 extend to near the bottom of the filter panel 3.The vertical channel 5 is connected to the inlet cross channel 6. Theinlet cross channel 6 extends from the left side of the vertical channel5 to the far right vertical channel 5. The height of the inlet crosschannel 6 might be 0.3 microns and would preferably be the same depth asthe vertical channels 5. There are a large number of inlet crosschannels 6 that might be spaced at one micron.

All of the inlet cross channels 6 may be connected to the verticalchannel 5. The inlet cross channels 6 would all be of similar length.Above the inlet cross channel 6 is the outlet cross channel 8. The crosschannel dividing wall 9 separates the inlet cross channel 6 from theoutlet cross channel 8. All of the outlet cross channels 8 are connectedto the outlet vertical channel 10.

Referring to FIG. 27, where the back side of the filter panel 3 isshown. On the back side 15 of the filter panel there are shallowchannels 16. The shallow channels 16 are shown to start at around twomicrons from the top of edge 4 of the filter panels 3, although theshallow channels 16 could begin at the top edge or much further down thefilter panel 3.

In some embodiments, the shallow channels 16 may be extremely shallow insize, for example, only be 0.001 micron deep. Again, the depth of thechannels would determine the size of the particle being filtered. Thewidth of the shallow channels 16 might be 0.08 microns. It will beunderstood that this dimension does not control the size of the particlebeing filtered. To filter extremely small particles an extremely shallowchannel is advantageous. It will be understood that with regard tomanufacturing small features, it is preferable to create shallowchannels as opposed to creating extremely narrow channels, although insome instances extremely narrow channels may be required and thus thefilter may be manufactured with such channels.

The shallow channels 16 extend down to near the bottom edge of thefilter panel and could as well extend to the bottom edge of the panel.In this embodiment, the shallow channels 16 are shown in a verticalorientation, although this orientation is not required. If the shallowchannels 16 are oriented at, for example, 30 degrees from normal (e.g.,parallel with the centerline of the filter), the vertical channels 5 andthe outlet vertical channels 10 may be oriented at the same angle. Inother words the shallow channels 16 may be parallel to the verticalchannels.

Referring to FIG. 28 the relationship of the various channels of afilter 2800 can be seen in a top section view. The shallow channels 16on the back side 15 of the filter panel 3 are connected to the crosschannel dividing wall 9 of the second filter panel 17 situated behindthe filter panel 3. This relationship allows fluid to flow from theinlet cross channels 6 to the outlet cross channels 8. The inlet crosschannel 6 is positioned below the cross channel dividing wall 9 and theoutlet cross channel 8 is above the cross channel dividing wall 9.

Referring to FIG. 29, the dashed line, outline 18, is shown toillustrate the location of the shallow channel 16 from the adjoiningpanel as it contacts the filter panel 3.

It should be noted that plastic or polymeric material is the preferredmaterial for the filter layers, although other materials could also beused such as composites, metals, glass, and ceramic—just to name a few.Both of these materials are not as easily molded as plastic materials,although they are typically more durable and can be operated at elevatedtemperatures. Ceramic and glass are typically not rolled into a tightspiral except when the thickness of the panel is much smaller than thebend radius. The disclosed film dimensions would allow for a glass orceramic film to be bent into a spiral.

While various embodiments have been described above, it should beunderstood that they have been presented by way of example only, and notlimitation. The descriptions are not intended to limit the scope of thetechnology to the particular forms set forth herein. Thus, the breadthand scope of a preferred embodiment should not be limited by any of theabove-described exemplary embodiments. It should be understood that theabove description is illustrative and not restrictive. To the contrary,the present descriptions are intended to cover such alternatives,modifications, and equivalents as may be included within the spirit andscope of the technology as defined by the appended claims and otherwiseappreciated by one of ordinary skill in the art. The scope of thetechnology should, therefore, be determined not with reference to theabove description, but instead should be determined with reference tothe appended claims along with their full scope of equivalents.

What is claimed is:
 1. A filter device, comprising: a plurality ofpanels with a filtering surface, the filtering front surface comprising:a first row of vertically extending protrusions spaced apart from oneanother to form channels, the first row proximate an inlet of the filterdevice; a second row of vertically extending protrusions spaced apartfrom one another to form channels, the second row proximate an exit ofthe filter device; and one or more additional rows of filteringprotrusions, the one or more additional rows being vertically spacedapart from one another and extending between the first and second rowsof vertically extending protrusions, each row of filtering protrusionscomprising filtering protrusions that are spaced from one another toform filter channels; and wherein the plurality of panels are stacked ina mating configuration such that the filtering front surface of onepanel is in mating contact with a flat back surface of an adjacentpanel.
 2. The filter device according to claim 1, wherein the width anddepth of each of the rows of filtering protrusions defines a filteringchannel.
 3. The filter device according to claim 1, wherein theadditional one or more rows of filtering protrusions are verticallyarranged between the first and second rows of vertically extendingprotrusions such that filter channels of the one or more rows filteringprotrusions are progressively smaller towards the exit of the filter. 4.The filter device according to claim 1, wherein filtering protrusions ofadjacent rows are offset from one another.
 5. The filter according toclaim 1, wherein one or more filtering protrusions of a row of filteringprotrusions comprises a filter groove that is configured to filterobjects that are smaller in size than objects that are captured by thefilter channels of the row.
 6. The filter according to claim 1, whereinthe plurality of panels each comprise a pair of flanges that aredisposed on outer edges of the panel.
 7. The filter according to claim1, further comprising a separation wall disposed between a first row anda second row of filtering protrusions, wherein the separation walldirects fluid around the second row of filtering protrusions.
 8. Thefilter according to claim 1, wherein the filtering protrusions aresquare in shape.
 9. The filter according to claim 1, wherein at leastone of the one or more rows of filtering protrusions comprises filteringprotrusions that have rounded edges of a given radius or fillets. 10.The filter according to claim 1, wherein the first row of verticallyextending protrusions have rounded edges of a given radius or filletsand the second row of vertically extending protrusions have roundededges of a given radius or fillets.
 11. The filter according to claim 1,wherein at least one of the rows of filtering protrusions comprisesfiltering protrusions that are tapered to produce filter channels thatare each narrower at an inlet end and larger at an outlet end to ensurethat objects are trapped in the narrower inlet end.
 12. The filteraccording to claim 1, further comprising one or more coating layersdisposed between adjacent rows of filtering protrusions.
 13. The filteraccording to claim 12, wherein the one or more coating layers arehydrophobic, dipole-dipole, ionic, or combinations thereof.
 14. Thefilter according to claim 1, further comprising a coating layer appliedto at least one of the one or more rows of filtering protrusions,wherein the coating layer is hydrophobic, dipole-dipole, ionic, orcombinations thereof.
 15. The filter according to claim 1, wherein anyof the first or second rows of vertically extending protrusions extendnormally from the flat back surface at a height that is greater than aheight at which the one or more rows of filtering protrusions extendfrom the flat back surface.
 16. The filter according to claim 1, whereinat least a portion of the filtering front surface is electricallycharged.
 17. The filter according to claim 1, wherein the one or moreadditional rows of filtering protrusions are disposed at an anglerelative to either or both of the first and second rows of verticallyextending protrusions.
 18. The filter according to claim 1, wherein atleast one of the panels is rolled onto itself to form a spiral that islayered such that at least a portion of the filtering front surfacemates with the flat back surface.
 20. The filter according to claim 1,wherein at least one of the panels is rolled into a cylindricalconfiguration.
 21. A substrate panel for filtering a fluid, thesubstrate panel, comprising: a filtering front surface and a flat backsurface, the filtering front surface comprising: a first row ofvertically extending protrusions spaced apart from one another to formvertical channels, the first row proximate an inlet of the substratepanel; a second row of vertically extending protrusions spaced apartfrom one another to form vertical channels, the second row proximate anexit of the substrate panel; and one or more additional rows offiltering protrusions, the one or more rows being vertically spacedapart from one another and extending between the first and second rowsof vertically extending protrusions.
 22. The substrate panel accordingto claim 21, wherein the substrate panel is rolled onto itself to form aspiral that is layered such that at least a portion of the filteringfront surface mates with the flat back surface.
 23. The substrate panelaccording to claim 22, wherein the substrate panel is rolled into acylindrical configuration.
 24. The substrate panel according to claim21, wherein the width and depth of each of the rows of filteringprotrusions defines a filtering channel.
 25. The substrate panelaccording to claim 21, wherein the additional one or more rows offiltering protrusions are vertically arranged between the first andsecond rows of vertically extending protrusions such that filterchannels of the additional one or more rows filtering protrusions areprogressively smaller towards the exit of the filter.
 26. The substratepanel according to claim 21, wherein filtering protrusions of adjacentrows are offset from one another.
 27. The substrate panel according toclaim 21, wherein one or more filtering protrusions of a row offiltering protrusions comprises a filter groove that is configured tofilter objects that are smaller in size than objects that are capturedby the filter channels of the row.
 28. The substrate panel according toclaim 21, wherein each panel comprises a pair of flanges that aredisposed on outer edges of the panel.
 29. The substrate panel accordingto claim 21, further comprising a separation wall disposed between afirst row and a second row of filtering protrusions, wherein theseparation wall directs fluid around the second row of filteringprotrusions.
 30. The substrate panel according to claim 21, wherein thefiltering protrusions are square in shape.
 31. The substrate panelaccording to claim 21, wherein at least one of the one or more rows offiltering protrusions comprises filtering protrusions that have roundededges of a given radius or fillets.
 32. The substrate panel according toclaim 21, wherein the first row of vertically extending protrusions haverounded edges of a given radius or fillets and the second row ofvertically extending protrusions have rounded edges of a given radius orfillets.
 33. The substrate panel according to claim 21, wherein at leastone of the rows of filtering protrusions comprises filtering protrusionsthat are tapered to produce filter channels that are each narrower at aninlet end and larger at an outlet end to ensure that objects are trappedin the narrower inlet end.
 34. The substrate panel according to claim21, further comprising one or more coating layers disposed betweenadjacent rows of filtering protrusions.
 35. The substrate panelaccording to claim 21, wherein the one or more coating layers arehydrophobic, dipole-dipole, ionic, or combinations thereof.
 36. Thesubstrate panel according to claim 21, further comprising a coatinglayer applied to at least one of the one or more rows of filteringprotrusions, wherein the coating layer is hydrophobic, dipole-dipole,ionic, or combinations thereof.
 37. The substrate panel according toclaim 21, wherein any of the first or second rows of verticallyextending protrusions extend normally from the flat back surface at aheight that is greater than a height at which the one or more rows offiltering protrusions extend from the flat back surface.
 38. Thesubstrate panel according to claim 21, wherein at least a portion of thefiltering front surface is electrically charged.
 39. The substrate panelaccording to claim 21, wherein the one or more additional rows offiltering protrusions are disposed at an angle relative to either orboth of the first and second rows of vertically extending protrusions.